Containers intended for moisture-sensitive products

ABSTRACT

A container for a moisture-sensitive product. The container has an openable container body defining an interior volume for holding the product. More specifically, a rigid container defining an interior volume for holding a moisture-sensitive product, and comprising at least an inner layer and an outer layer, the inner and outer layers being coextruded layers, the inner layer comprising a polymeric material and a desiccant material, the outer layer comprising a moisture-barrier material.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 11/670,801 filed on Feb. 2, 2007. This Application is also a continuation-in-part of U.S. application Ser. No. 11/461,680 filed on Aug. 1, 2006, which is a continuation-in-part of U.S. application Ser. No. 11/401,633 filed on Apr. 11, 2006, now abandoned, which was a continuation-in-part of U.S. application Ser. No. 10/385,131 filed on Mar. 10, 2003, which is a continuation-in-part of U.S. application Ser. No. 10/175,662 filed on Jun. 20, 2002. These applications are incorporated herein in their entirety.

FIELD OF THE INVENTION

This disclosure relates to the packaging of products that are sensitive to moisture, such as medicines or consumer goods produced in powder, pill, tablet, capsule, pastille, granule, gelcap or other forms, and which can become damaged or deteriorated if exposed to moist air over time. More particularly, the present disclosure relates to rigid containers used for packaging such products, particularly re-closable containers, and to methods for production of such containers.

BACKGROUND OF THE INVENTION

Many medicaments and other ingestible or non-ingestible consumer products are adversely affected if exposed to moisture or moist air for a period of time and must be protected against such exposure between production and consumption. The damage may take the form of moisture absorption that changes the physical properties of the products (e.g. making pills or particles of powder clump together) or even chemical change or corrosion. When such products are produced and sold in small amounts and in discrete unit form (e.g. pills or tablets), they are often sealed in re-closable containers made of glass or plastics, such as conventional pill or tablet bottles, to which a desiccant, in the form of a sachet or packet, is added to remove any moisture from the enclosed atmosphere.

A conventional desiccant sachet is inserted into the container with the product itself. The desiccant sachet is important because it acts to remove any moisture that may permeate into the container during storage or transportation and also acts to remove moisture that may have entered the container when a consumer opens or closes the container. Because the desiccant sachet is free floating within the container, there is therefore a risk that the sachet or packet or canister may be removed once the container has been opened but before the product has been completely used up, thereby placing remaining product at risk of moisture damage. Also, there is a risk that the sachet may rupture or be accidentally consumed along with the product itself, thus creating a hazard for the user. It is also to be noted that the production and insertion of such sachet or packet or canister adds an undesired cost to the production of the product. In addition, there is a risk that the inserting equipment will miss inserting the sachet, packet or canister into the container, thereby leaving the consumable product unprotected and subject to premature loss of efficacy.

BRIEF SUMMARY OF THE INVENTION

According to the present disclosure, there is provided a container for a moisture-sensitive product, comprising: a container body defining an interior volume for holding a moisture-sensitive product, wherein the container body is made of a rigid material comprising at least two co-extruded polymer layers, i.e., an inner one comprising a desiccant, and an outer layer comprising a solid, non-porous moisture-barrier material.

Following the present disclosure, it is possible to create a container in which there is an inner layer having a desiccant moisture scavenger in intimate contact or near intimate contact with any moisture within the interior volume of the container. Following the present disclosure, the desiccant is protected from abrasion that would lead to mixing of the desiccant with the contents of the container. The container may nevertheless have the desired strength and rigidity required for transportation and storage of the contained product.

Furthermore, it is an advantage of aspects of the present invention to create a container having more than one type of desiccant material incorporated therein to take advantage of the unique moisture uptake characteristics of the selected desiccant materials employed. In addition, different combinations of types of desiccant materials may be utilized, thereby allowing for specifically selected relative humidity levels within the containers.

Also described herein are methods for producing containers for a moisture sensitive product.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting embodiments will now be described with reference to the accompanying drawings.

FIG. 1 is a vertical cross-section of a container according to one embodiment of the present invention.

FIG. 2 is a graph illustrating weight gain versus time for a test carried out on one embodiment of a container of the kind shown in FIG. 1 at 90% relative humidity and at 120° F.

FIG. 3 is graph illustrating weight gain versus time at various relative humidities for a test carried out on one embodiment of a container of the kind shown in FIG.

FIG. 4 is a graph illustrating the relative humidity control by various desiccants versus time.

FIG. 5 is a graph illustrating relative humidity % versus time with respect to one embodiment of a container of the kind shown in FIG. 1.

FIG. 6 is a graph illustrating projected product moisture gain for a CaO desiccant container of one embodiment of the kind shown in FIG. 1.

FIG. 7 is a graph illustrating projected product protection of a desiccant container of one embodiment of the kind shown in FIG. 1 compared to a HDPE container without desiccant.

FIG. 8 is a vertical cross-section of a container according to another embodiment of the present invention.

FIG. 9 is a vertical cross-section of a container according to another embodiment of the invention.

FIG. 10 illustrates the recovery from 50% relative humidity at 73° F. (23° C.) for particular containers in accordance with the invention as compared to a control container.

FIG. 11 illustrates recovery speed from High RH Exposure in 50% RH for particular containers in accordance with the invention as compared to a control container.

FIG. 12 is an isometric view of a container according to a further embodiment of the invention.

FIG. 13 is a horizontal cross-section illustration of the embodiment in FIG. 12.

DETAILED DESCRIPTION OF EMBODIMENTS

The containers and methods disclosed herein advantageously can allow the manufacturer of these containers to limit the risks and hazards posed by most commonly used forms of desiccants used today, and can allow containers to be made more efficiently and cost effectively. The desiccant in the containers disclosed herein cannot be readily removed from the containers by consumers. This in turn allows for the product within the container to be continually protected from moisture and prevents consumers from accidentally ingesting the desiccant material. The containers and methods disclosed herein can eliminate the steps of making a separate desiccant containing liner, sachet, packet or canister and then inserting the separate desiccant containing liner, sachet, packet or canister into containers.

In coextrusion or coinjection methods disclosed herein, a manufacturer can mass produce a container comprising a layer comprising a desiccant material, wherein the layer comprising the desiccant material can be the inner layer of the container in intimate or near intimate contact with moisture sensitive product to be held within the container, or the desiccant layer can be encapsulated near the interior with a protective layer of breathable polymer. In the coextrusion or coinjection methods disclosed herein, a manufacturer can simply coextrude or coinject materials into a mold that corresponds to the container to be formed. In the coextrusion or coinjection methods disclosed herein, a manufacturer can readily switch to making a different sized container by simply using a different mold corresponding to the different sized container, and coextruding or coinjecting the same materials into that subsequently used mold. Methods of production and process included can be coextrusion blow molding, coinjection molding, coinjection blow molding, and/or coinjection stretch blow molding.

Where a layer comprising desiccant is coextruded or coinjected with at least an outer layer of the container, the coextrusion and coinjection methods disclosed herein can eliminate the risk of failing to insert a separate desiccant containing liner into containers and the quality control measures associated with that risk.

Furthermore, the desiccant material may be contained within one or more of the layers of the container structure. For example, the desiccant may be contained within the inner layer of a structure so moisture from the container headspace may quickly be taken up. The container structure may be utilized to produce containers such as a bottle, a vial, or a package, for example lidstock with a formed sheet cover, for a moisture-sensitive product.

Embodiments of the present invention incorporate both chemical desiccants and physical desiccants in the same container structure. The use of two types of desiccant allows the desirable features of both desiccants to be utilized. For example, physical desiccants, such as molecular sieves, will rapidly remove moisture from inside a container. When the molecular sieves cease to adsorb moisture, such as at a humidity level of about 10% RH, the chemical desiccant will absorb the remaining moisture until the humidity level in the container is below about 3% RH. Another example illustrates the cooperation between a hydrate forming physical desiccant and a chemical desiccant. Hydrate forming desiccants are salts that take up water more rapidly than chemical desiccants, but as noted above, hydrate forming salts that have adsorbed moisture may then breathe some of the water molecules back into the air. The presence of a chemical desiccant, such as calcium oxide, in the container structure with the hydrate forming salt would cause the released moisture to be removed again when it is absorbed by the calcium oxide.

Due to the rapid rate of water adsorption by physical desiccants, the processing of polymeric blends that contain such desiccant materials may be difficult. A very dry atmosphere is required to minimize the amount of moisture adsorbed during handling and processing of the desiccant into a product. A chemical desiccant, in contrast, may be handled and incorporated into a product with fewer process constraints as a result of the relatively slow uptake of moisture by chemical desiccants. When a chemical desiccant and a physical desiccant are both included in the product, the chemical desiccant will keep the physical desiccant dry so that it can be processed without the need for additional drying materials or nearly constant storage in barrier packaging.

An example of a container 11 for moisture sensitive products is shown in FIG. 1 of the accompanying drawings. Container 11 is in the form of a plastic bottle. While a bottle is shown in FIG. 1, those skilled in the art will recognize that a wide variety of containers can be made in accordance with disclosures herein, including but not limited to bottles, canisters (e.g., canisters for 35 mm film), vials (e.g., vials for pharmaceutical products), etc. A cross-sectional area defined by a neck of the container can be smaller, larger or the same size as a cross-sectional area defined by the side wall of the container. Container 11 and a closure or lid 12 form a container and lid combination 10. Lid 12 in some embodiments can attach to the container 11 via a screw thread 13 formed on a neck 14 of container 11 that engages with a corresponding thread on an inner surface 15 of a skirt 16 of the lid 12. Container 11 defines an internal volume 18 that encloses the product (not shown) in the completed form of the package. In alternative forms, container 11 can have a different shape or appearance from that shown in FIG. 1. If desired, container and lid combination 10 may be provided in the conventional way with an anti-tamper feature. Such a feature would, of course, have to be removed before the contents could be accessed.

Container 11 can be a rigid, semi-rigid, or flexible container made of multiple layers of plastic resin(s) 20. In one embodiment, the multiple layers of plastic resin(s) can be such that when formed into a container, the container retains its molded shape under gravity (when empty or when filled with product) but, if desired, may be flexible enough to be indented when squeezed by hand. Even when indented by hand, the material can return to its original shape when released, even when the container is open. In one embodiment, the side wall of the container can have a thickness of about 15 mils or greater. In a further embodiment, the side wall of the container can have a thickness of about 15 to 110 mils. In a further embodiment, the side wall of the container can have a thickness of about 103 mils, with an outer layer 21 of the side wall being about 30 mils thick and an inner layer 22 of the side wall being about 73 mils thick. In one embodiment, the density of the side wall can be around 0.888 grams/cc or greater.

Container 11 may preferably be formed by a process called coextrusion or coinjection. Specifically, different layers of material comprising container 11 can be coextruded in a multilayer coextrusion blow molding process, coinjection molding, co-injection blow molding, and/or co-injection stretch blow molding. Other extrusion processes can be used, such as cast and tubular water quench extrusion processes.

While the following discussion focuses on formation of container 11, the same discussion can apply equally to formation of closure or lid 12.

Container 11 may be made of at least two different coextruded layers 21 and 22 of plastic material. Specifically, layers 21 and 22 may be coextruded as a hot molten tube containing the multiple layers 20 of plastic material. Container 11 can then be made from the tube by conventional blow-molding techniques. The layers 21 and 22 may also be co-injection molded into a finished container or that co-injection item, while still hot, may be blow molded into a finished container, dependent upon the desired container shape, using co-injection blow molding or co-injection stretch blow molding techniques.

In one embodiment, polymers for the different layers are extruded separately and then brought together in a die, which co-extrudes them as a multilayer tube. During the manufacturing process, this tube can be located in a mold having cavity portions cut into it which together define the shape of container 11. The cavity portions can be closed onto the multilayer tube by pinching the tube at the top and the bottom to form a sealed tube. The tube can be pierced at the top and air can be injected to inflate the multilayer tube to fit the shape of the cavity of the mold. The mold can be opened and the multilayered container can be removed. The container can be trimmed of flash at the bottom and top where the multilayer tube was pinched shut.

Layer 21, the outer layer of container 11, can be made of any conventional thermoplastic resin material used for containers of this kind. In one embodiment, layer 21 comprises high density polyethylene (HDPE) (e.g., polyethylene having a density of about 0.95 to 0.96 g/cc and having chains which are virtually linear, that is, virtually no side chain branching), but other extrudable resins may be used, such as cyclic olefin copolymers, polypropylene, other polyethylenes, nylon and polyesters. The resin comprising layer 21 should have a high resistance to penetration by moisture when present in the shaped container. In one embodiment, layer 21 should preferably act as a barrier layer to substantially block the penetration of moisture. This may be assured both by choosing an appropriate resin and also by providing the layer with a suitable thickness.

Layer 22, the inner layer of container 11, can comprise a desiccant blended within a resin. Layer 22 should be minimally exposed to any ambient moist air before, during and after extrusion and blow molding as the desiccant is susceptible to moisture take-up during processing. The formulation of the resin for layer 22 should be such that it can be extruded in a manner that allows adhesion to an adjoining layer of the container, as well as providing appropriate rheology during melting, processing and forming. The nature of the resin and the amount used is preferably such that, in the final container, the resin in layer 22 is permeable to water vapor and moisture so that the desiccant in layer 22 may act to keep the interior of the container dry. Some potential resins for use in layer 22 include linear low density polyethylene, low density polyethylene, polypropylene homopolymers, polypropylene copolymers, polyethylene naphthalate, cellulose acetate butyrate, ethyl cellulose, polycarbonate, nylon, polysulfone, polyether sulfone, polyethylene terephthalate, cyclic olefin homopolymers and cyclic olefin copolymers. By having a desiccant in layer 22, a foil seal, such as a foil induction seal, can be used to provide a seal after product is placed within the open space defined by the container. This decreases or eliminates the need to have a desiccant sachet or desiccant insert placed within the container, and reduces or eliminates the need for a desiccant placed in the lid or cap in order to protect product placed in the container from being adversely effected by moisture.

The above described construction can provide enhanced package integrity by reducing or eliminating the need to align and register a sachet into a finished package, and can reduce or eliminate the need to slow line filling speed for sachet and/or insert placement within a container, and can reduce the possibility of contamination, such as dust, from entering the container. The above described construction can provide lower headspace relative humidity (RH) because the desiccant in layer 22 never leaves the container and is always exposed to product placed within the container and/or the open space defined by the container.

The starting material for layer 22 may also contain a small proportion of a foaming or blowing agent, e.g. a heat-sensitive blowing agent that commences “foaming” of the resin at the time it exits the extruder. Specifically, in those cases where the layer 22 is intended to be provided with open pores in the resin that allow better contact of the desiccant in the layer with the atmosphere within the enclosed volume 18, a blowing agent is incorporated into the resin mixture intended to form the inner layer 22. Because layer 22 has numerous pores as a result of the foaming of the blowing agent, the desiccant material has a greater surface area exposure to the container's open space, including headspace between product placed within the container and the lid of the container, thereby enabling a faster acting desiccant layer as compared to those layers which have not been exposed to a blowing agent. A blowing agent can be selected that is heat-activated at a temperature suitable for the resin co-extrusion step so that the blowing agent forms a gas as the resin mixture is extruded through the die slot. Thus, as layer 22 is formed, the gas can create pores in the resin and the pores can remain in the resin as layer 22 contacts and adheres to layer 21 to form a multiple layer tube which is later molded into container 11. The amount of blowing agent employed in the resin mixture should be appropriate to produce an open-pore structure in container 11 without disintegrating or weakening the resin matrix of layer 22. Normally, the minimum amount of blowing agent that can achieve the desired porosity is employed. This amount depends on the actual blowing agent employed.

Suitable blowing agents for this purpose may be physical or chemical blowing agents. Physical blowing agents undergo only physical change. The most common are low-boiling organic liquids, such as hydrocarbons (normal pentane, iso-pentane and cyclo pentane) and halogenated hydrocarbons, which develop cells within the plastic material by changing from liquid to gas during foaming under the influence of heat. Gases (e.g. nitrogen gas) constitute another group of substances belonging to this class. When physical blowing agents are used in foaming, therefore, the gas phase of the foam is chemically identical with the blowing agent. Chemical blowing agents are materials that are stable at normal storage temperature and under specific processing conditions, but undergo decomposition with controllable gas evolution at reasonably well defined temperatures (or reaction conditions). When they are used in foaming, the gas phase of the resulting foam is different from the blowing agent (usually a solid substance). Blowing agents of this class can be organic nitrogen compounds (e.g., azodicarbonamide), and produce, mainly, nitrogen gas along with smaller proportions of other gases.

The resulting layer 22 can be porous and allow greater contact between moisture and the desiccant in the formed layer 22. The type of blowing agent and its concentration in the resin may affect the number of pores formed in the final layer 22 and the size of the pores, so suitable choices can be made to produce a product of the required specifications. The resin used for this layer may be different from the resin used for layer 21, but it may be the same, e.g. a high density polyethylene.

The desiccant blended into the resin or polymeric material used for layer 22 could be a powdered solid that is mixed with the molten resin before co-extrusion takes place. The amount of desiccant can be sufficient to provide the required drying action in the interior volume 18 of the finished container 10. The ratio of desiccant to resin can be the highest amount that can run successfully in the extrusion and blow molding equipment. The ratio may often range from 5 parts by weight of desiccant to 95 parts by weight of resin, to 80 parts by weight of desiccant to 20 parts by weight of resin. In one embodiment, the ratio can be approximately 10 to 25 parts by weight desiccant to approximately 75 to 90 parts by weight resin. In a particular embodiment, the ratio can be about 50:50 by weight. In one embodiment, the desiccant material can be a Calcium Oxide (CaO) desiccant concentrate.

Another embodiment incorporates a chemical desiccant material into layer 22 at a level of between about 1 weight percent and about 60 weight percent of the total weight of layer 22. In one embodiment, the desiccant material may be incorporated into layer 22 at a level of between about 20 weight percent and about 60 weight percent. In another embodiment, the desiccant material may be incorporated into the layer 1 at a level of between approximately 20 weight percent and approximately 40 weight percent. In an additional embodiment, the desiccant material may be incorporated into layer 22 at a level of approximately 30 weight percent.

In an embodiment, layer 22 may comprise a quantity of a masterbatch of polymer and desiccant material. For example, the masterbatch may preferably comprise polyethylene having calcium oxide blended therein. Specifically, the masterbatch may comprise about 50 percent by weight polyethylene and about 50 percent by weight calcium oxide. The masterbatch can be further blended into another polymeric material, such as low density polyethylene, in a ratio of about 60 percent by weight masterbatch and 40 percent by weight low density polyethylene. Therefore, layer 22, in an embodiment, may have a desiccant material content of about 30 weight percent in the layer 22.

Physical desiccants may also be used, and may effectively maintain fairly constant relative humidity levels within the headspace of a container including layer 22. The physical desiccants may include material such as molecular sieves or hydrate forming salt desiccants. Various levels of humidity may be maintained depending on the hydration levels or state of the hydrate forming salt within the polymer material. The physical desiccant may be molecular sieves, sodium phosphate di-basic, potassium carbonate, magnesium chloride or calcium sulfate.

In an embodiment, layer 22 may comprise a quantity of a masterbatch of polymer and a chemical desiccant material and a quantity of a masterbatch of polymer and a physical desiccant material blended with another polymeric material. Specifically, the masterbatch of polymer and chemical desiccant may comprise about 50 weight percent polyethylene about 50 weight percent chemical desiccant material. The masterbatch of polymer and physical desiccant may comprise about 80 weight percent polyethylene and about 20 weight percent physical desiccant. For example, an embodiment of layer 22 may comprise about 45 weight percent of the chemical desiccant masterbatch, about 25 weight percent of the physical desiccant masterbatch and about 30 percent of a polyethylene polymer. The resulting layer 22 would thus comprise about 22.5 weight percent chemical desiccant and about 5 weight percent physical desiccant.

The combined thicknesses of the two layers 21 and 22 can provide the container with the required rigidity and durability to meet commercial performance requirements. Specifically, when the resin employed in the layers is high density polyethylene, the outer layer 21 can have a thickness in the range of about 20 to 50 mils, and in a more particular embodiment about 30 mils, and the inner layer 22 can have a thickness in the range of about 10 to 25 mils, and in a more particular embodiment about 15 mils. The total thickness of the combined multiple layers 20 may be, for example, 45 mils. The total thickness can be less than or greater than embodiments above.

Closure or lid 12 may be a conventional closure or lid, e.g. a lid made of injection-molded high density polyethylene. In one embodiment, there would be no desiccant in the lid. In another embodiment, the lid 12 can contain a desiccant and can be made of the same or similar double-layer structure as the container body 11, if desired. The closure can be of any suitable thickness.

In another embodiment it is also possible to use three or more co-extruded layers to form the container 11. For example, inner layer 22 and outer layer 21 discussed above may be separated by a thin co-extruded intermediate layer 50 with a very high resistance to penetration by moisture. See FIG. 8. This further reduces moisture ingress into the container and thus extends the useful life of the desiccant and therefore the shelf life of the packaged product. While FIG. 8 shows intermediate layer 50 being thicker than inner layer 22, intermediate layer 50 can have the same thickness as inner layer 22, or be thinner than inner layer 22. In an embodiment, a suitable material for the intermediate layer can be, for example, polyvinylidene chloride, ethylene vinyl alcohol, or a fluoropolymer resin sold by Honeywell under the trademark Aclon, or polychlorotrifluoroethylene (PCTFE) sold under the trademark Aclon. Intermediate layer 50 can comprise a material having a higher moisture resistance or a lower moisture resistance than the moisture-barrier material in the outer layer.

FIG. 9 illustrates a container comprising more than three layers to form the container. As shown in FIG. 6, an adhesive resin layer 60 can separate inner layer 22 and intermediate layer 50, and adhesive layer 62 can separate intermediate layer 50 and outer layer 21. Adhesive resin layers 60 and 62 can be made of any suitable resin that adheres to other resin layers. Examples of adhesive resins include but are not limited to Bynel® (by DuPont), Plexar® (by Equistar Chemical Company), and Admer® SF600 (by Mitsui Chemicals America, Inc.).

The desiccant employed may be any one that is able to withstand the handling, blending, co-extrusion and blow-molding steps without deterioration, and it can be such that it has a drying effect that is consistent with the maximum moisture content to be permitted within the interior volume 18 according to the product to be packaged, as well as a suitable long-term activity. The desiccant may be a so-called “physical” desiccant, e.g. a molecular sieve (zeolite) that binds water within its pore space, silica gel or clays having the ability to absorb water on their surfaces or within pore spaces of the material.

Typically, the drying capacity of a physical desiccant material is greatly influenced by the relative humidity within a container. Generally, no water is taken up by a hydrate-forming desiccant until the relative humidity reaches a value at which the first hydrate forms. In the case of calcium chloride, for example, the first hydrate occurs at less than about two percent relative humidity (RH). Water is then taken up by the hydrate forming salt until the first hydrate is completely formed by the salt. No further water is taken up by the salt until the relative humidity reaches a second level where the second hydrate forms. This process continues through as many hydrates as the agent forms at which point the substance begins to dissolve and a saturated solution is formed. The saturated solution will then continue to take up water.

Although these desiccant salts may be effective at removing water molecules from a quantity of gas that may be contained within the headspace of a container, since the salt only binds the water molecules within the salt, the water molecules may easily escape back into the headspace. This is known as breathing, and may cause deliquescence (water droplets and liquidization) inside the package. Typically, this can happen if the salt becomes saturated and if the temperature of the container increases, or if the pressure of the container decreases, which may occur during shipment or storage.

In addition, salts may not allow moisture levels within a container to fall to a level that is necessary to protect a moisture-sensitive product within the container. Since salts usually have different levels of hydration, humidity levels may remain at certain level without decreasing until the level of hydration changes. However, these salts may be utilized to maintain certain humidity levels within the headspace of a container. For example, certain products may require that a certain level of moisture or humidity be maintained within the container headspace. Headspace humidity control for products can be manipulated by incorporation of the appropriate hydrate forming desiccants.

An example of using a molecular sieve with calcium oxide is a blend of the following: 50% HDPE+50% Blend: 75% CaO and 25% Molecular Sieve. So-called “chemical” desiccants (reactive materials) may therefore be more preferable as the absorption may not be reversible and the moisture level within the container may be maintained at an extremely low level. Examples of chemical desiccants are magnesium oxide, aluminum oxide and calcium oxide. Calcium oxide absorbs moisture according to the following equation: CaO+H₂O→Ca(OH)₂

For practical purposes, the reaction is irreversible and the resulting Ca(OH)₂ is insensitive to heat and pressure. The CaO reactant is capable of absorbing water at all humidity levels and can continue to take up water until it is completely consumed.

A container structure having both a chemical desiccant layer and a molecular sieve desiccant layer may also be provided. The dual desiccant container structure can be used in place of a single desiccant layer or can be used in addition to a single desiccant layer.

In one aspect of the invention, the second desiccant layer is located between the first desiccant layer and the barrier layer. The second desiccant layer can absorb moisture that enters from the outside of the multilayer container structure. It also can act as a backup desiccant in the event that the first desiccant layer becomes saturated. The first desiccant layer and the second desiccant layer may or may not comprise the same desiccant material. In one aspect of the invention, the first and second desiccant layers include chemical desiccants. In another aspect of the invention, one of the desiccant layers includes a chemical desiccant and the other includes both a molecular sieve desiccant and a chemical desiccant.

In another aspect of the invention, a single container layer can incorporate several different types of desiccant. In one embodiment, a desiccant layer 22 can incorporate a chemical desiccant and a molecular sieve desiccant. In an embodiment, the desiccant layer 22 can include approximately 5-35% by weight chemical desiccant, approximately 5-35% by weight molecular sieve desiccant and approximately 30-90% by weight polymeric materials such as polyethylene, linear low density polyethylene or other polymeric materials

The desirable size of the desiccant particles is dependent on the actual desiccant employed. For example, when CaO is used, particles having a size of less than about 0.003 inches in diameter can be used. Larger desiccant particle sizes can create a grainy appearance. However, in certain embodiments, larger desiccant particles can be used.

Of course, the container need not be in the form of a bottle as shown in the drawings and may have any shape as required to accommodate a product to be packaged. FIGS. 12 and 13 illustrate a container 300 in an alternate embodiment of the present invention. More specifically, the container 300 may comprise a base structure 302 having multiple cavities 303 disposed therein for containing moisture-sensitive products therein. The base structure 302 may be formed having the same layers of materials as the bottle of FIG. 1, where layers 312 and 310 in FIG. 13 correspond to desiccant layer 22 and outer layer 21 of FIG. 1, respectively. Further, the base structure 302 comprises cavities 303 for storing or otherwise containing the moisture-sensitive products 305. The cavities 303 may preferably be formed in the base structure 302 using a thermoforming process or any other process for forming the cavities 303 in the base structure 302. The moisture-sensitive products 305 may preferably be pharmaceutical or nutraceutical products, such as quick dissolve tablets or other quickly dissolving pharmaceuticals, although any other moisture-sensitive product is contemplated by the present invention.

The base structure 302 may be heat-sealed to a lidstock structure 304. The lidstock structure may have a film structure as shown in FIG. 13. Specifically, a heat sealant layer 110 of the lidstock structure 304 may be heat-sealed to desiccant layer 312 of the base structure 302 that acts as a heat sealant layer for the base structure 302. The sealant layer 110 may also comprise the desiccant material so that moisture cannot enter the cavities 303 along an edge 326 to damage any moisture-sensitive products contained therein. Moreover, the sealant layer 110 may further comprise a peelable seal component to allow a seal formed by heat sealing the desiccant lidstock structure 304 to the base structure 302 to be easily peelable. For example, the sealant layer 110 may comprise polybutene, DuPont APPEEL® modified polymeric resin that allows the sealant layer 110 to separate from the forming layer 312 of the base structure 302 using digital pull-apart forces.

The container 300 may have perforations 306 such that the peelable film may only expose one cavity containing the moisture-sensitive product when the sealant film is peeled from the base structure. When the peelable sealant film structure is peeled from the base structure, the peelable sealant film structure may break at the perforations 306, thereby maintaining the barrier properties of the other products contained within the other cavities. The perforations 306 may alternately go all the way through the package 300 such that each individual cavity may be removed from the remaining cavities within the package by breaking the container 300 at the perforations 306.

Layer 22 can be U.S. FDA and regulatory compliant for direct contact with food or drug products to be placed within open space defined by the container.

The invention is described in more detail with reference to the following Examples that are not intended to limit the scope of the present invention and are merely illustrative.

EXAMPLE 1

A plastic bottle of the type shown in FIG. 1 was prepared by co-extrusion and blow-molding two resin layers as described above. The outer layer 21 was 30 mils in thickness and consisted of high density polyethylene (HDPE) sold under the trademark Exxon AD-60007. The inner layer 22 was 15 mils in thickness and consisted of a 50/50 by weight blend of the same high density polyethylene and a desiccant masterbatch. The masterbatch was a 50/50 by weight blend of calcium oxide (Ampacet™ grade 101499) and 21 melt index linear low density polyethylene. The inner layer 22 was 25% by weight calcium oxide.

The resulting bottle was subjected to tests to determine desiccant capacity, recovery from opening and projected product moisture gain, etc.

FIG. 2 is a graph illustrating weight gain versus time for a test carried out on a container of the kind shown in FIG. 1 at 90% relative humidity and at 120° F.

FIG. 3 is graph illustrating weight gain versus time at various relative humidity percentages (i.e., 11%, 20%, 32%, 43%, and 52%) for a container of the kind shown in FIG. 1.

FIG. 4 is a graph illustrating the relative humidity control by various desiccants (i.e., MgSO₄·X(H₂O), Calcium Oxide (CaO), and a molecular sieve. A molecular sieve is a moisture scavenger and can be made of a variety of suitable materials. A molecular sieve provides porous pathways and is a class of desiccant. The molecular sieve used this particular example was Ampacet 101787: 20% molecular sieve/80% carrier resin.

FIG. 5 is a graph illustrating relative humidity % versus time for a test carried out on a container of the kind shown in FIG. 1 upon normal opening, first saturation, and second saturation, respectively.

FIG. 6 is a graph illustrating projected product moisture gain for a CaO desiccant container of the kind shown in FIG. 1.

FIG. 7 is a graph illustrating projected product protection provided by a desiccant container of the kind shown in FIG. 1 compared to a HDPE container without desiccant.

Below are the testing protocol used in Example 1.

1. Measure moisture sorption capacity of the bottle as total weight gain over time when exposed to the following relative humidity (RH) conditions

Accelerated 120° F., 90% RH Ambient Theoretical Model

2. Measure impact of RH in headspace of bottle over time using data logger starting at 100° F. and 80% RH and 73° F. and 50% RH to determine lowest level of RH achieved.

3. Utilize control sample of Ampacet 101499 to determine available capacity of CaO in resin when started.

4. Determine via FTIR (i.e., Fourier Transformed Infrared Technique) the CaOH peak of bottle before, during and after the test to validate ability to measure CaO availability.

5. Use control sample of HDPE for determining MVTR barrier in comparison to the same thickness Moisture Scavenging bottle.

6. Use Desiccant model to determine anticipated moisture sorption capacity of the sample bottle to arrive at expected shelf stability at ambient and accelerated temperature and RH conditions of both control 100% HDPE and Desiccant bottle.

EXAMPLE 2

A plastic bottle of the type shown in FIG. 1 was prepared by co-extrusion and blow-molding resin layers as described above. Four (4) multilayer structures were made, as identified below. In each structure, the HDPE resin was Chevron-Phillips Marlex 5502BN. Also, WX0226 (Plastic Color Chip PEC14828 white color concentrate used at 6 pounds per 100 pounds of Chevron Phillips Marlex 5502BN) was added to the outer layer in each variable structure.

In this example, a similar bottle to that of Example 1 was prepared, except that the desiccant masterbatch used in Example 1 was replaced by a masterbatch containing 20% by weight of a molecular sieve and 80% by weight of 21 melt index linear low density polyethylene. The molecular sieve was found to speed recovery but was consumed at a faster rate than CaO, that is, the molecular sieve reached its saturation point faster than CaO.

Wall thickness approximately 50 mils.

Molding Process Co-extrusion Blow Molding: 3 Extruders, 8 station Lab Wheel; 2 cavities, 6 stations blanked off

Materials:

HDPE: Chevron Phillips Marlex HHM 5502BN HDPE (0.35 melt index, 0.955 HDPE hexene copolymer)

Color: WX0226: 6 lbs. PCC 14828 52% TiO₂+3.9% Zinc Stearate+44.1% PE=2.9% TiO₂ & 0.22% Zinc Stearate in molded layer

Desiccant: Ampacet 101499: 50% CaO/50% PE carrier resin

Molecular Sieve Ampacet 101787: 20% Molecular Sieve/80% carrier resin

Foaming Conc.: Ampacet 703061-H: 50% Sodium Carbonate Acid Foaming agent/50% carrier resin

Variant 1 (Control): “Monolayer” HDPE

-   -   A Outside Surface 15 mils Chevron Phillips Marlex HHM 5502BN         HDPE+WX0226 White     -   B Sandwiched Layer 15 mils Chevron Phillips Marlex HHM 5502BN         HDPE     -   C Product Contact Layer 20 mils Chevron Phillips Marlex HHM         5502BN HDPE

Variant 2: HDPE with Desiccant Layer, 35% CaO in Layer C

-   -   A Outside Surface 15 mils Chevron Phillips Marlex HHM 5502BN         HDPE+WX0226 White     -   B Sandwiched Layer 15 mils Chevron Phillips Marlex HHM 5502BN     -   C Product Contact Layer 20 mils 30% Chevron Phillips Marlex HHM         5502BN HDPE+70% Ampacet 101499 CaO conc.

Variant 3: HDPE/Desiccant Layer/Desiccant+Molecular Sieve Layer, 35% CaO in Layer B, 22.5% CaO & 5% Molec. Sieve in Layer C

-   -   A Outside Surface 30 mils Chevron Phillips Marlex HHM 5502BN         HDPE+WX0226 White     -   B Sandwiched Layer 20 mils 30% Chevron Phillips Marlex HHM         5502BN HDPE+70% Ampacet 101499 CaO conc.     -   C Product Contact Layer 5 mils 30% Chevron Phillips Marlex HHM         5502BN HDPE+45% Ampacet 101499 CaO conc.+25% Ampacet 101787

Variant 4: HDPE/Desiccant Layer/Foamed Desiccant Layer, 35% CaO Loading in Layer B, 34% CaO in Layer C

-   -   A Outside Surface 30 mils Chevron Phillips Marlex HHM 5502BN         HDPE+WX0226 White     -   B Sandwiched Layer 10 mils 30% Chevron Phillips Marlex HHM         5502BN HDPE+70% Ampacet 101499 CaO conc.     -   C Product Contact Layer 10 mils 30% Chevron Phillips Marlex HHM         5502BN HDPE+68% Ampacet 101499 CaO conc.+2% Ampacet 703061-H         foaming conc.

Test Method and Conditions:

1. Measure moisture sorption capacity of the bottle as total weight gain over time when exposed to the following Relative Humidity (RH) conditions: Accelerated 120° F., 90% RH; Ambient Theoretical Model 73° F., 50% RH.]

2. Measure impact of RH in headspace of bottle over time using data logger starting at 100° F. & 80% RH and 73° F. & 50% RH to determine lowest level of RH achieved.

3. Utilize control sample of Ampacet 101499 to determine available capacity of CaO in resin when started.

4. Determine via FTIR the CaOH peak of bottle before, during and after the test to validate ability to measure CaO availability.

5. Use control sample of HDPE for determining MVTR barrier in comparison to the same thickness Moisture Scavenging bottle.

6. Use Desiccant model to determine anticipated moisture sorption capacity of the sample bottle to arrive at expected shelf stability at ambient and accelerated temperature and RH conditions of both control 100% HDPE and Desiccant bottle.

The resulting bottles were subjected to tests to determine recovery from 50% relative humidity at 73° F. (23° C.). The results for Variable Structures 1, 2, 3, and 4 are shown in FIG. 10. Variations in bottle wall thickness or seals may have a bearing on the minimum RH obtained. Also, variations in sensor calibrations may lead to small differences.

FIG. 11 illustrates recovery speed from High RH Exposure in 50% RH for particular containers in accordance with the invention as compared to a control container.

While particular embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations may be apparent from the foregoing descriptions without departing from the spirit and scope of the invention as defined in the appended claims. 

1. A method for making a multilayer container, comprising: providing a first masterbatch comprising a chemical desiccant of calcium oxide, a physical desiccant of silica clay and a first polymeric material; providing a second polymeric material; blending the first masterbatch and the second polymeric material to form a subsequent blend, wherein the calcium oxide is present at a range of from about 20 to about 60 weight percent of the subsequent blend; forming the subsequent blend and a third polymeric material into a preform via co-extrusion or via co-injection molding; including a sole desiccant layer between the subsequent blend and the third polymeric material; and blow-molding the preform to form the container, wherein the subsequent blend of the container comprises a thickness of about 20 to 73 mils.
 2. The method of claim 1, wherein the step of blending further comprises blending a blowing agent with the first masterbatch and the second polymeric material.
 3. The method of claim 1, wherein the first polymeric material and the second polymeric material are the same polymeric material.
 4. The method of claim 1, wherein the step of forming comprises forming a shape selected from the group consisting of a bottle, a vial, and a formed sheet with lidstock.
 5. The method of claim 1, wherein the step of forming further comprises including a barrier layer between the subsequent blend and the second polymeric material.
 6. The method of claim 1, wherein the desiccant layer comprises calcium oxide.
 7. A method for making a multilayer component, comprising: providing a first masterbatch comprising a chemical desiccant of calcium oxide, a physical desiccant of silica clay and a first polymeric material; providing a second masterbatch comprising a physical desiccant and a second polymeric material; blending the first masterbatch and the second masterbatch with a third polymeric material to form a subsequent blend, wherein the calcium oxide is present at a range of from about 20 to about 60 weight percent of the subsequent blend; and forming the subsequent blend and a layer of high density polyethylene or polypropylene into the component via co-injection or co-extrusion blow molding, wherein the subsequent blend comprises a thickness of about 20 to 73 mils, wherein the step of forming further comprises including a moisture barrier layer between the subsequent blend and the layer of high density polyethylene or polypropylene.
 8. The method of claim 7, wherein the barrier layer comprises a material selected from the group consisting of polyvinylidene chloride, ethylene vinyl alcohol, a fluoropolymer resin and polychlorotrifluoroethylene.
 9. A method for making a multilayer container, comprising: providing a first masterbatch comprising a first chemical desiccant material, a first physical desiccant material and a first polymeric material; providing a second polymeric material; blending the first masterbatch and the second polymeric material to form a subsequent blend; and forming the subsequent blend and a third polymeric material into the container using a process selected from the group consisting of co-extrusion blow molding, co-injection molding, co-injection blow molding and co-injection stretch molding, wherein the container consists of two layers, wherein the first polymeric material and the second polymeric material are independently selected from the group consisting of linear low density polyethylene, low density polyethylene, medium density polyethylene, high density polyethylene, polyethylene, polypropylene homopolymers, polypropylene copolymers, polyethylene naphthalate, cellulose acetate butyrate, ethyl cellulose, polycarbonate, polysulfone, polyether sulfone, cyclic olefin homopolymers and cyclic olefin copolymers, and wherein the third polymeric material is selected from the group consisting of linear low density polyethylene, low density polyethylene, medium density polyethylene, high density polyethylene, polyethylene, polypropylene homopolymers, polypropylene copolymers, cyclic olefin copolymers and polyesters.
 10. The method of claim 9, wherein the first chemical desiccant material comprises calcium oxide.
 11. The method of claim 10, wherein the calcium oxide is present at a range of from about 20 to about 60 weight percent of the subsequent blend.
 12. The method of claim 9, wherein the first polymeric material is high density polyethylene.
 13. The method of claim 9, wherein the second polymeric material is high density polyethylene.
 14. The method of claim 10, wherein the third polymeric material is an inner layer of the container and the first physical desiccant material is silica clay, the method further comprising: providing a desiccant within the inner layer. 